Building Component and Method

ABSTRACT

According to an aspect of the invention, a building component includes a central layer, such as a foam panel, having first and second opposite faces, and a hardened surface, such as a concrete-based substance, applied to at least one of the faces of the foam layer. The foam layer can include at least one channel. The hardened surface is applied to the face such that it extends within the channel. The building component can also include a reinforcing member, such as a length of rebar, disposed within the channel. A process of fabricating a building component includes providing the foam layer, and applying the hardened surface to at least one of the faces of the foam layer.

CROSS-REFERENCE TO RELATED APPLICATION

This is related to and claims priority from U.S. Provisional Patent Application Ser. No. 61/242,433, which was filed on Sep. 15, 2009.

FIELD OF THE INVENTION

The invention relates to building components, such as walls and other load-bearing structures, and for buildings and other structures constructed from these components. The invention also relates to processes for fabricating such building components, and for constructing buildings using such building components.

BACKGROUND OF THE INVENTION

There are many designs and fabrication methods and systems for walls and other load-bearing structures used in the construction industry. Such designs must balance the need for sturdy structures that will be long-lasting and can handle the stresses and loads of the given application, that are suitable for being finished in a manner that is suitable for the given application, and that are cost-effective. Cost-effectiveness of building components must take into account not only the cost of materials, but also the cost of fabrication and construction, of which ease and speed of fabrication are factors, as are weight and durability. There is always a need for a building component that is light-weight and strong, and that can be fabricated inexpensively and quickly on-site using commonly-fund materials, and which can easily be fabricated according to custom specifications.

BRIEF SUMMARY OF THE INVENTION

The invention encompasses a building component, a building structure, a process of fabricating a building component, and a process of constructing a building structure.

According to an aspect of the invention, a building component includes a central layer, such as a foam layer, having first and second opposite faces, and a hardened surface applied to at least one of the faces of the central layer.

The central layer can include at least one channel within the first face. In this case, the hardened surface is applied to the first face such that it extends within the at least one channel. The channel can have a transverse cross-section having, for example, a geometric shape, such as a triangular, semicircular, rectangular, or tee cross-section.

The central layer can include a number of channels within the first face. For example, the channels can be mutually substantially parallel. Alternatively, the channels can form a grid. In this case, the grid can include a first set of channels that are mutually substantially parallel, and a second set of channels that are mutually substantially parallel and substantially perpendicular to the first set of channels.

The central layer can also include at least one channel within the second face. The hardened surface can be applied to the second face such that it extends within the at least one channel.

The building component can also include a reinforcing member disposed within the at least one channel. For example, the reinforcing member can be a length of rebar.

The hardened surface can be a concrete-based substance, or a non-concrete substance such as Grancrete®.

According to another aspect of the invention, a building structure includes a number of the building components described above.

According to another aspect of the invention, a process of fabricating a building component includes providing a central layer, such as a foam layer, having first and second opposite faces, and applying a hardening material to at least one of the faces of the central layer.

The process can include forming at least one channel within the first face, and applying the hardening material to the first face such that the hardening material extends within the at least one channel. The channel can be formed to have a transverse cross-section having, for example, a geometric shape, such as a triangular, semicircular, rectangular, or tee cross-section.

The process can include forming a number of channels within the first face, such that the channels are mutually substantially parallel. Alternatively, the channels can form a grid. For example, the grid can be formed to include a first set of channels that are mutually substantially parallel, and a second set of channels that are mutually substantially parallel and substantially perpendicular to the first set of channels.

The process can include forming at least one channel within the second face, and applying the hardening material to the second face such that the hardening material extends within the at least one channel.

The process can also include disposing a reinforcing member within the channel. For example, the reinforcing member can be a length of rebar.

The hardening material can be, for example, a concrete-based substance, or a non-concrete substance such as Grancrete®.

The process can include applying a viscous material to the face of the central layer, and allowing the viscous material to harden. The hardened material can be allowed to cure, if necessary. The outer surface of the hardened material can be finished as appropriate.

According to another aspect of the invention, a process of constructing a building structure includes assembling a plurality of building components including the building components described above.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram of a foam core of an exemplary embodiment of the invention.

FIG. 2 is a diagram showing the hardened surface applied to the foam core of an exemplary embodiment of the invention.

FIG. 3 is a diagram showing a cross-section of an exemplary embodiment of the invention.

FIG. 4 is a diagram showing cross-sectional views of various exemplary embodiments of the present invention.

FIG. 5 is a diagram showing an exemplary building structure of the invention.

DETAILED DESCRIPTION OF THE INVENTION

As shown in FIG. 1, a core element of the building component 1 is a central layer 2, preferably in the form of a panel. This panel is preferably made of a lightweight material, such as foam. For example, this foam panel can be made of expanded poly-styrene (E.P.S.), or a similar material that can function as the core of building component. Preferably, this panel is generally planar in shape, with optional inset channels 10 formed in either face or in both faces. It is contemplated that other panel shapes, such as curves or irregular shapes, can also be used. As shown in FIG. 4, these channels can take regular geometric shapes, such as the triangular 3, semi-circular 4, rectangular 5, and “tee” 6 shapes shown. It is contemplated that other geometric shapes or amorphous shapes can be used, and that the channels formed in a particular panel need not all have the same shape. The channels can be regularly spaced, as shown, or irregularly spaced according to the application. The panels can be pre-formed with the channels in place, or the channels can be cut from a planar sheet.

The channels formed in the central layer can be arranged in any suitable manner. For example, the channels can be formed such that they are mutually substantially parallel, forming regular columns. Alternatively, the channels can form a grid of perpendicular sets of mutually parallel channels, or curved central layers can include helixically-shaped channels. The channels can be cut or otherwise removed from a solid panel of the central layer, or the central layer can be molded with pre-set channels.

Thus, when the layer of hardened material is applied, the channels act as forms that are filled to create studs spaced along the face of the panel. The channels can be filled as part of the same process by which the self-hardening mixture is applied to the panel surface, or can be sprayed, troweled, poured, adhered, bonded, welded, strapped, held to, or applied/installed in any other way in a separate step. The end result is a structural building component having a lightweight central core, a hardened outer shell, and spaced rigid studs within the foam core.

As shown in FIG. 2, a hardening material 7, preferably in viscous form, is applied to at least one face, and preferably to both faces, of the central layer 2. The applied material is allowed to harden, and to cure if necessary, resulting in hardened surfaces on the faces of the panel. The surface can be finished, such as by sanding or applying a coating or texture, such as stucco, to the surface. The hardening material is preferably applied to each face such that it extends within any channels 10 formed in the face as described above.

Any type of hardening material can be used as the surface material. For example a concrete-based substance can be used, although non-concrete materials, such as Grancrete® can also be used as appropriate to the application. Shotcrete and gunite are also suitable materials, and it will be apparent to those of skill in the art that other materials can be advantageously used as well. The material can be troweled, sprayed, or otherwise applied to cover the faces of the central layer.

A cross-sectional view of an exemplary building component 1 according to the invention is shown in FIG. 3. This embodiment includes an optional reinforcing member 8 disposed within at least one channel, for example, in the form of a length of rebar. This optional element will add structural integrity to the building component, particularly if the component is to be used as a load-bearing component. Other materials such as metal, plastic, or wood can be added to the channel as reinforcement, or to the surface of the component for ornamentation.

As shown in FIG. 5, a number of the inventive building components 1 can be assembled together using any known means in order to construct any type of building structure 9. For example, the building component can be fabricated on-site as a wall unit, which can then be used to construct the interior or exterior space of a building as would any conventional wall unit.

The building component can also be laid flat as flooring, or used in any other application. More than one such building component can be stacked or arranged in any combination, geometric shape, or design to contract a complete structure or item that is not limited by the panel design. Once fabricated, individual building components 1 can be cut to size or shape to suit the particular application. Individual completed components can be connected by means known to those of skill in the art, and component ends and edges can have hardening material 2 or other finishing material applied so that the cross-sectional composition of the component is not exposed. Alternatively, numerous central layers can be arranged into a structural shape prior to forming the channel studs and applying the hardened outer surface.

Particular exemplary embodiments of the present invention have been described in detail. These exemplary embodiments are illustrative of the inventive concept recited in the appended claims, and are not limiting of the scope or spirit of the present invention as contemplated by the inventors. 

1. A building component, comprising: a central layer having first and second opposite faces; and a hardened surface applied to at least one of the faces of the central layer.
 2. The building component of claim 1, wherein the central layer is a foam panel.
 3. The building component of claim 1, wherein the central layer includes at least one channel within the first face, wherein the hardened surface is applied to the first face and extends within the at least one channel.
 4. The building component of claim 3, wherein the at least one channel has a transverse cross-section having a geometric shape selected from the group consisting of triangular, semicircular, rectangular, and tee.
 5. The building component of claim 3, wherein the central layer includes a plurality of the channels within the first face, wherein the channels are mutually substantially parallel.
 6. The building component of claim 3, wherein the central layer includes a plurality of the channels within the first face, wherein the channels form a grid.
 7. The building component of claim 6, wherein the grid includes a first set of channels that are mutually substantially parallel, and a second set of channels that are mutually substantially parallel and substantially perpendicular to the first set of channels.
 8. The building component of claim 3, wherein the central layer also includes at least one channel within the second face, wherein the hardened surface is applied to the second face and extends within the at least one channel.
 9. The building component of claim 3, further comprising a reinforcing member disposed within the at least one channel.
 10. The building component of claim 9, wherein the reinforcing member is a length of rebar.
 11. The building component of claim 1, wherein the hardened surface is a concrete-based substance.
 12. A building structure, comprising a plurality of the building components as recited in claim
 1. 13. A process of fabricating a building component, comprising: providing a central layer having first and second opposite faces; and applying a hardening material to at least one of the faces of the central layer.
 14. The process of claim 13, wherein the central layer is a foam panel.
 15. The process of claim 13, further comprising forming at least one channel within the first face, and applying the hardening material to the first face such that the hardening material extends within the at least one channel.
 16. The process of claim 15, further comprising forming the at least one channel to have a transverse cross-section having a geometric shape selected from the group consisting of triangular, semicircular, rectangular, and tee.
 17. The process of claim 15, comprising forming a plurality of the channels within the first face, such that the channels are mutually substantially parallel.
 18. The process of claim 15, comprising forming the plurality of the channels within the first face such that the channels form a grid.
 19. The process of claim 18, comprising forming the grid to include a first set of channels that are mutually substantially parallel, and a second set of channels that are mutually substantially parallel and substantially perpendicular to the first set of channels.
 20. The process of claim 15, further comprising forming at least one channel within the second face, and applying the hardening material to the second face such that the hardened surface extends within the at least one channel.
 21. The process of claim 15, further comprising disposing a reinforcing member within the channel.
 22. The process of claim 21, wherein the reinforcing member is a length of rebar.
 23. The process of claim 13, wherein the hardening material is a concrete-based substance.
 24. The process of claim 13, wherein applying the hardening material to at least one of the faces of the central layer includes applying a viscous material to the at least one of the faces of the central layer, and allowing the viscous material to harden.
 25. The process of claim 24, further comprising allowing the hardened material to cure.
 26. The process of claim 24, further comprising finishing the outer surface of the hardened material.
 27. A process of constructing a building structure, comprising assembling a plurality of building components including the building components fabricated according to claim
 13. 